Method and device for adjusting welding assembly gap of copper bar of motor controller

Abstract

The invention relates to the technical field of motor tools, in particular to a motor controller copper bar welding assembly clearance adjusting method and device, a vehicle and a storage medium, and the method comprises the steps that a motor controller part finite element simulation model is established, the relative position of the model is adjusted according to the copper bar position tolerance, and the limit working condition in a tolerance zone is simulated; under the working condition, applying a displacement load to a tool pressure head, simulating pressing of a part, and obtaining copper bar welding area gap and part stress data; determining a tool pressure head displacement range meeting a preset welding process requirement according to the welding area gap, determining reference stress data according to the tool pressure head displacement range, and adjusting the welding area gap according to the reference stress data and the part stress data so as to adjust the copper bar assembly gap. Therefore, the problems of long copper bar welding period, insufficient theoretical and actual connection, incapability of effectively identifying the failure mode of the plastic structure and the like are solved.

Description

Technical Field

[0001] This application relates to the field of motor tooling technology, and in particular to a method, device, vehicle, and storage medium for adjusting the welding assembly gap of the copper busbar of a motor controller. Background Technology

[0002] In related technologies, the tooling displacement is initially determined by theoretical calculation or empirical formula, and the condition of the plastic shell is observed by combining the bidirectional bending test of the sample. However, the copper busbar welding process is long, the connection between theory and practice is insufficient, and only surface cracks or deformation can be observed, which cannot effectively identify the failure mode of the plastic structure. Summary of the Invention

[0003] This application provides a method, device, vehicle, and storage medium for adjusting the welding assembly gap of copper busbars in a motor controller, in order to solve problems such as long welding time for copper busbars, insufficient connection between theory and practice, and inability to effectively identify failure modes of plastic structures in related technologies.

[0004] The first aspect of this application provides a method for adjusting the welding assembly gap of a copper busbar in a motor controller, comprising the following steps: establishing a finite element simulation model of a component in the motor controller; simulating the finite element simulation model of the component being installed on the motor controller; adjusting the relative position of the finite element simulation model according to the positional tolerance of the copper busbar to simulate the extreme working conditions within the tolerance zone; applying a displacement load to the tooling head of the motor controller under the extreme working conditions within the tolerance zone to simulate the pressing process of the component in the motor controller; obtaining the welding area gap of the copper busbar and the stress data of the component during the pressing process; determining the displacement range of the tooling head that meets the preset welding process requirements based on the welding area gap; determining reference stress data based on the displacement range of the tooling head; and adjusting the welding area gap based on the reference stress data and the stress data of the component to adjust the copper busbar assembly gap.

[0005] According to one embodiment of this application, the components in the motor controller include IGBT copper busbars, IGBT plastic housings, IGBT heat sinks, AC copper busbars, AC busbar plastic housings, and multiple tooling heads.

[0006] According to one embodiment of this application, a finite element simulation model of components in a motor controller is established, including: acquiring component data of the motor controller; identifying component names, material properties, and contact relationships in the component data; determining component models based on component names; assigning material properties and contact relationships to the corresponding components in the component models; and establishing a finite element simulation model of the components in the motor controller based on the component models.

[0007] According to one embodiment of this application, the material properties include at least one of the elastic modulus, Poisson's ratio, and stress-strain curve.

[0008] According to one embodiment of this application, the limiting conditions within the tolerance zone include at least one of the following: maximum clearance condition, maximum interference condition, highest position condition allowed by the tolerance zone, and lowest position condition allowed by the tolerance zone.

[0009] According to one embodiment of this application, before applying a displacement load to the tooling head of the motor controller under the extreme working condition within the tolerance zone, the method further includes: identifying whether the extreme working condition within the tolerance zone is the maximum interference condition; if the extreme working condition within the tolerance zone is the maximum interference condition, then obtaining the prestress data and deformation data simulated by the finite element model under the maximum interference condition.

[0010] According to one embodiment of this application, applying a displacement load to the tooling head of a motor controller under extreme operating conditions within the tolerance zone includes: obtaining a pre-set displacement load curve; and applying a displacement load to the tooling head of the motor controller based on the displacement load curve under extreme operating conditions within the tolerance zone.

[0011] A second aspect of this application provides an adjustment device for the welding assembly gap of a copper busbar in a motor controller, comprising: a modeling module for establishing a finite element simulation model of a component in the motor controller, simulating the finite element simulation model of the component being installed on the motor controller, and adjusting the relative position of the finite element simulation model according to the positional tolerance of the copper busbar to simulate the extreme working conditions within the tolerance zone; a pressing module for applying a displacement load to a tooling head of the motor controller under the extreme working conditions within the tolerance zone to simulate the pressing process of the component in the motor controller, and obtaining the welding area gap of the copper busbar and component stress data during the pressing process; and an adjustment module for determining the tooling head displacement range that meets the preset welding process requirements based on the welding area gap, determining reference stress data based on the tooling head displacement range, and adjusting the welding area gap based on the reference stress data and component stress data to adjust the copper busbar assembly gap.

[0012] A third aspect of this application provides a vehicle, which includes a motor controller. The welding assembly gap of the copper busbar of the motor controller is adjusted using the aforementioned method for adjusting the welding assembly gap of the copper busbar of the motor controller.

[0013] A fourth aspect of this application provides a computer-readable storage medium having a computer program stored thereon, which is executed by a processor to implement the method for adjusting the welding assembly gap of the copper busbar of a motor controller as described in the above embodiments.

[0014] Therefore, this application has the following beneficial effects: A finite element simulation model of the components in the motor controller is established. This model is then installed on the motor controller, and the relative position of the finite element simulation model is adjusted according to the positional tolerance of the copper busbar to simulate the extreme working conditions within the tolerance zone. This accurately reproduces the extreme working conditions within the tolerance zone, allowing for simulation calculations of the extreme working conditions in the early stages of structural design. Under these extreme working conditions, a displacement load is applied to the tooling head of the motor controller to simulate the pressing process of the components. Data on the weld gap of the copper busbar and the stress of the components during the pressing process are obtained. The pressing of the components is then evaluated based on this data, eliminating the need for repeated testing with physical components and saving R&D costs and time. The displacement range of the tooling head that meets the pre-set welding process requirements is determined based on the weld gap. Reference stress data is then determined based on the displacement range of the tooling head. The weld gap is adjusted based on the reference stress data and the component stress data to adjust the copper busbar assembly gap. This ensures that the copper busbar assembly meets the welding process requirements and guarantees the structural safety of the components during assembly through stress data, accurately identifying failure conditions in the plastic structure. This solves the technical problems of long welding time for copper busbars, insufficient connection between theory and practice, and inability to effectively identify failures in plastic structures.

[0015] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0016] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: Figure 1 This is a diagram showing the internal structure of a motor controller according to an embodiment of this application; Figure 2 This is a flowchart illustrating a method for adjusting the welding assembly gap of a motor controller copper busbar according to an embodiment of this application; Figure 3 This is a flowchart illustrating an embodiment of a method for adjusting the welding assembly gap of a motor controller copper busbar according to an embodiment of this application; Figure 4 This is a graph showing the displacement relationship between the welding area and the tooling according to an embodiment of this application. Figure 5 This is an example diagram of an adjustment device for the welding assembly gap of the copper busbar of a motor controller according to an embodiment of this application; Figure 6 This is a structural schematic diagram of a vehicle according to an embodiment of this application. Detailed Implementation

[0017] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0018] Partial structure of the motor controller as follows Figure 1 As shown, the internal components include IGBT copper busbar 11, AC copper busbar 12, IGBT plastic housing 13, AC busbar plastic housing 14, IGBT heat sink 15, and tooling head 16. During the assembly of the motor controller, the IGBT module copper busbar 11 and AC copper busbar 12 need to be welded together. However, due to errors such as positional tolerances during component manufacturing and assembly, the areas to be welded on the copper busbars may not fit tightly in the initial assembly state, resulting in gaps exceeding the welding process requirements.

[0019] Therefore, in the actual process, the copper busbar needs to be clamped using the tooling head 16 to adjust its relative position. The key to this process is to reasonably set the displacement of the tooling head: if the displacement is too small, the gap cannot be effectively eliminated; if the displacement is too large, the copper busbar may be excessively deformed, which will cause the gap to increase again. At the same time, since the copper busbar is usually covered with a certain rigidity injection-molded plastic shell 13, 14, this plastic structure will bear a large stress during the tooling pressing process. Therefore, the reasonable tooling displacement must simultaneously meet the following requirements: 1. Adjust the gap of the area to be welded to within the allowable range of the process; 2. Ensure that the plastic structural parts are not damaged.

[0020] The following describes, with reference to the accompanying drawings, a method, apparatus, vehicle, and storage medium for adjusting the welding assembly gap of the copper busbar in a motor controller according to embodiments of this application. Addressing the problems mentioned in the background art, such as long welding time for copper busbars, insufficient connection between theory and practice, and inability to effectively identify failure modes of plastic structures, this application provides a method for adjusting the welding assembly gap of the copper busbar in a motor controller. In this method, a finite element simulation model of the components in the motor controller is established. This finite element simulation model of the simulated components is installed on the motor controller. The relative position of the finite element simulation model is adjusted according to the positional tolerance of the copper busbar to simulate the extreme working conditions within the tolerance zone. Under the extreme working conditions within the tolerance zone, a displacement load is applied to the tooling head of the motor controller to simulate the pressing process of the components in the motor controller. During the pressing process, the welding area gap of the copper busbar and the stress data of the components are obtained. Based on the welding area gap, a tooling head displacement range that meets the preset welding process requirements is determined. Reference stress data is determined based on the tooling head displacement range. The welding area gap is adjusted based on the reference stress data and the component stress data to adjust the copper busbar assembly gap. This solves the problems of long welding time for copper busbars, insufficient connection between theory and practice, and inability to effectively identify failure modes of plastic structures.

[0021] Specifically, Figure 2 This is a flowchart illustrating a method for adjusting the welding and assembly gap of a motor controller copper busbar, as provided in an embodiment of this application.

[0022] like Figure 2 As shown, the method for adjusting the welding gap of the copper busbars in the motor controller includes the following steps: In step S201, a finite element simulation model of the components in the motor controller is established. The finite element simulation model of the simulated component is installed on the motor controller. The relative position of the finite element simulation model is adjusted according to the position tolerance of the copper busbar to simulate the extreme working conditions within the tolerance zone.

[0023] Understandably, the method for adjusting the welding assembly gap of the copper busbar in the motor controller of this application utilizes finite element software to simulate and calculate the components in the early stages of structural design. The finite element simulation model is a digital model established based on the finite element analysis method. Simulation using this model allows for testing without the need for prototype manufacturing and can visually present potential design flaws. Positional tolerance refers to the allowable range of variation of the actual component relative to the theoretical reference position. By adjusting the relative position of the finite element simulation model, simulating the extreme working conditions within the tolerance zone, the availability and safety of the motor controller under extreme operating conditions can be verified, preventing motor controller failure due to extreme conditions during actual use and ensuring long-term stable operation of the equipment.

[0024] According to one embodiment of this application, the components in the motor controller include IGBT copper busbars, IGBT plastic housings, IGBT heat sinks, AC copper busbars, AC busbar plastic housings, and multiple tooling heads.

[0025] It is understandable that the internal structure of the motor controller is as follows: Figure 1 As shown, the internal components include IGBT copper busbar 11, AC copper busbar 12, IGBT plastic housing 13, AC busbar plastic housing 14, IGBT heat sink 15, and tooling head 16. This application uses simulation models to determine the displacement range of the tooling head 16, i.e., the distance the tooling head 16 moves from the AC copper busbar 12, thereby adjusting the area to be soldered between the IGBT copper busbar 11 and the AC copper busbar 12 to a reasonable range. When determining the displacement range of the tooling head 16, it is necessary to ensure that the plastic structural components, the IGBT plastic housing 13 and the AC busbar plastic housing 14, are not damaged.

[0026] For example, the IGBT copper busbar 11 is close to the AC copper busbar 12 and is installed above the IGBT plastic housing 13; the AC copper busbar 12 is installed above the IGBT plastic housing 13 and adjacent to it; the IGBT copper busbar 11 and the AC copper busbar 12 are installed above the IGBT plastic housing 13, adjacent to the IGBT heat sink base plate 15 below, and adjacent to the AC busbar plastic housing 14 on the side; the AC busbar plastic housing 14 is adjacent to the IGBT plastic housing 13 and adjacent to the tooling head 16 above it; the IGBT heat sink base plate 15 is located below the IGBT plastic housing 13 and adjacent to it; the tooling head 16 is located above the AC busbar plastic housing 14 and adjacent to it.

[0027] According to one embodiment of this application, a finite element simulation model of components in a motor controller is established, including: acquiring component data of the motor controller; identifying component names, material properties, and contact relationships in the component data; determining component models based on component names; assigning material properties and contact relationships to the corresponding components in the component models; and establishing a finite element simulation model of the components in the motor controller based on the component models.

[0028] Understandably, by acquiring component data from the motor controller, the geometry, dimensions, and spatial layout of each component are determined, providing a basis for constructing an accurate digital model. Material properties in the component data refer to the physical characteristics of the materials used in the components, determining their response to conditions such as temperature during simulation. For example, the elastic modulus of the material affects the degree of deformation of the component. Contact relationships refer to the interaction forms between components, such as bonding, contact, and sliding. Material properties and contact relationships ensure the accuracy and reliability of the finite element simulation model.

[0029] For example, taking the IGBT copper busbar 11 in the motor controller as an example, firstly, its component name is identified as "IGBT copper busbar 11", its material properties are the mechanical and thermal properties of copper, and its contact relationship is close to the AC copper busbar 12, while being installed above the IGBT plastic housing 13; then, according to the name of the IGBT copper busbar 11, the material properties of copper are assigned to the geometric model, and the contact type between it and the AC copper busbar 12 and the IGBT plastic housing 13 is defined in the model; finally, the IGBT copper busbar 11 model with material properties and contact relationship is assembled with other component models that have been processed in a similar way (such as AC copper busbar 12, IGBT plastic housing 13, etc.) to establish the finite element simulation model of the components in the motor controller.

[0030] According to one embodiment of this application, the material properties include at least one of the elastic modulus, Poisson's ratio, and stress-strain curve.

[0031] Understandably, the elastic modulus reflects the stiffness of a material in the relationship between external force and elastic deformation. The larger the elastic modulus, the more difficult the material is to be stretched or compressed. Poisson's ratio describes the relationship between lateral deformation and axial deformation of a material under unidirectional force. When a material is stretched, the axial side lengthens and the lateral side contracts; when compressed, the axial side shortens and the lateral side expands. Poisson's ratio is the ratio of these two strains. The stress-strain curve uses "strain" as the abscissa and stress as the ordinate, intuitively describing the entire process of a material under external force from elastic deformation to plastic deformation and then to fracture. It can directly reflect multiple key parameters such as elastic modulus, Poisson's ratio, strength, and plasticity.

[0032] For example, establish the material parameters for the IGBT copper busbar, IGBT plastic housing, IGBT heat sink, AC copper busbar, AC busbar plastic housing, and tooling head. The tooling head uses rigid body properties, while the material properties of other components include the elastic modulus. Poisson's ratio and stress-strain curves.

[0033] In step S202, a displacement load is applied to the tooling head of the motor controller under extreme working conditions within the tolerance zone to simulate the pressing process of the components in the motor controller and obtain the welding area gap of the copper busbar and the stress data of the components during the pressing process.

[0034] It is understandable that displacement load refers to a fixed displacement amount applied in the direction of motion of the tooling head, conforming to the dimensional tolerance limits of the components. In actual motor controller assembly, the tooling head needs to press down according to a preset stroke, and the displacement load directly reproduces this stroke-based control process. At the same time, the extreme working conditions within the tolerance zone mean that the displacement amount must cover the boundary values ​​of the component dimensional tolerances to ensure that the simulation results can cover the most stringent pressing scenarios. By obtaining the welding area gap of the copper busbar and the stress data of the components during the pressing process, the displacement load parameters of the tooling head, the dimensional tolerances of the components, and the rationality of the structural design can be determined.

[0035] According to one embodiment of this application, the limiting conditions within the tolerance zone include at least one of the following: maximum clearance condition, maximum interference condition, highest position condition allowed by the tolerance zone, and lowest position condition allowed by the tolerance zone.

[0036] Understandably, the maximum clearance condition is when the copper busbar, within the allowable positional tolerance range, shifts to its limit away from the adjacent component that needs alignment, reaching its maximum actual spatial distance from that component; the maximum interference space is when the copper busbar, within the allowable positional tolerance range, shifts to its limit towards the adjacent component with spatial constraints, reaching its maximum spatial overlap with that component; the highest positional condition allowed by the tolerance zone refers to the state where, with a preset height reference, the actual position of the copper busbar within the vertical positional tolerance zone reaches its upper limit offset limit; the lowest positional condition allowed by the tolerance zone refers to the state where, with a preset height reference, the actual position of the copper busbar within the vertical positional tolerance zone reaches its lower limit offset limit.

[0037] For example, based on the positional tolerance of the copper busbar, the relative position of the model is adjusted to simulate the extreme working conditions within the tolerance zone. The clamping conditions include at least the following: 1. Maximum clearance condition: The clearance between the IGBT copper busbar and the AC copper busbar is the maximum allowable value of the tolerance zone. This means the clearance to be eliminated is the largest, and the AC copper busbar is positioned at its lowest point under the premise of the maximum clearance. The required tooling displacement is also greater. 2. Maximum interference condition: The interference between the IGBT copper busbar and the AC copper busbar is the maximum allowable value of the tolerance zone. This results in the greatest assembly stress and deformation of the structure. The IGBT copper busbar is positioned at its highest point under the premise of the maximum interference. The stress caused by the tooling pressing down is also greater. 3. Maximum allowable position of the tolerance zone condition: Both the IGBT copper busbar and the AC copper busbar are at the highest position allowed by the tolerance zone. Under this condition, the overall structural stiffness is the greatest, and the stress caused by the tooling pressing down is the greatest under the same displacement. 4. Minimum allowable position of the tolerance zone condition: Both the IGBT copper busbar and the AC copper busbar are at the lowest allowable position of the tolerance zone. When the initial clearance of the copper busbar is acceptable, this condition is required to ensure that the tooling can contact the copper busbar after pressing down. When the initial clearance is unacceptable, the tooling displacement required under this condition may be the greatest.

[0038] According to one embodiment of this application, before applying a displacement load to the tooling head of the motor controller under the extreme working condition within the tolerance zone, the method further includes: identifying whether the extreme working condition within the tolerance zone is an interference condition; if the extreme working condition within the tolerance zone is a maximum interference condition, then obtaining the prestress data and deformation data simulated by the finite element model under the maximum interference condition.

[0039] Understandably, in interference fit conditions, the mutual compression of copper busbars generates assembly stress and deformation, requiring the calculation of prestress and deformation data. In other conditions, such as gap fit conditions, the copper busbars are not in contact and no compression occurs. The highest and lowest position fit conditions may also be interference fit conditions, requiring the calculation of prestress and deformation data. It should be noted that this application does not cover this situation. Prestress data refers to the pre-existing stress distribution data within the system after the copper busbars and accessories are assembled under interference fit conditions, before any external working load is applied; it represents the internal stress generated by the interference compression during assembly. Deformation data refers to the quantitative data of the shape or size changes of the copper busbars due to interference compression after assembly under maximum interference fit conditions. Maximum interference fit conditions refer to the maximum interference between the IGBT copper busbars and the AC copper busbars, with the AC copper busbars at the highest position allowed by the tolerance zone. In this case, it is necessary to obtain the prestress and deformation data simulated by the finite element model under the maximum interference fit conditions.

[0040] For example, in cases where there is interference between copper busbars to be welded, a solver needs to be used to solve the computational model to obtain the prestress data and deformation data of the model.

[0041] According to one embodiment of this application, applying a displacement load to the tooling head of a motor controller under extreme operating conditions within the tolerance zone includes: obtaining a pre-set displacement load curve; and applying a displacement load to the tooling head of the motor controller based on the displacement load curve under extreme operating conditions within the tolerance zone.

[0042] Understandably, the displacement load curve reflects the relationship between the displacement and the assembly stress borne by the tooling head, clearly showing how the assembly stress borne by the tooling head changes with the displacement during the application process. Applying displacement load to the tooling head of the motor controller based on the displacement load curve allows for early prediction of stress risks, preventing damage to the tooling head, and accurately matching extreme operating conditions, ensuring the effectiveness of the application process and making the assembly results more reliable.

[0043] For example, the relative position of the model is adjusted according to the positional tolerance of the copper busbar, the extreme working conditions within the tolerance zone are simulated, and the displacement load curve is defined. The displacement load is applied to the tooling head, and the simulation data of each working condition in the simulation process are evaluated in the next step to determine the general tooling displacement.

[0044] In step S203, the tooling head displacement range that meets the pre-set welding process requirements is determined based on the welding area gap. Reference stress data is determined based on the tooling head displacement range. The welding area gap is adjusted based on the reference stress data and component stress data to adjust the copper busbar assembly gap.

[0045] Understandably, this adjustment logic prioritizes meeting welding process requirements. First, it determines the initial displacement range that allows the gap to conform to the process range by matching the correspondence between the welding area gap and the tooling head displacement. Then, it obtains the stress data of the components based on this displacement range and sets reference stress data for structural safety based on material properties. Finally, it compares the actual component stress data with the reference stress. If the stress exceeds the standard, it finely adjusts the displacement to reduce the stress. By determining the displacement through the gap, determining the reference stress based on the displacement, and adjusting the gap based on the reference stress, it ultimately finds a balance between a qualified welding gap and safe component stress, achieving precise adjustment of the copper busbar assembly gap.

[0046] The following will illustrate the method for adjusting the welding assembly gap of the copper busbar in a motor controller through a specific embodiment. The process for adjusting the welding assembly gap of the copper busbar in a motor controller is as follows: Figure 3 As shown, the details are as follows: In step S301, a finite element simulation model of the motor controller copper busbar clamping condition is established. This model includes a three-dimensional finite element mesh model of the IGBT copper busbar, IGBT plastic housing, IGBT heat sink, AC copper busbar, AC busbar plastic housing, and tooling pressure head. Element types C3D6, C3D8I, and C3D10M are selected. The mesh contact surfaces between the copper busbar and the associated plastic structure are treated with shared nodes to ensure good mesh quality at all mating surfaces and surrounding areas, as well as at the chamfers of the IGBT plastic housing and the AC busbar plastic housing. After mesh generation, the model is assembled according to the actual positional relationships.

[0047] In step S302, material parameters are established for the IGBT copper busbar, IGBT plastic housing, IGBT heat sink, AC copper busbar, AC busbar plastic housing, and tooling head. The tooling head uses rigid body properties, and its material parameters must include at least the elastic modulus and Poisson's ratio. Stress-strain curves are also required for the material parameters of the IGBT copper busbar, IGBT plastic housing, AC copper busbar, and AC busbar plastic housing. Material properties are assigned to each component of the simulation model. The contact relationships between the components of the simulation model are defined. The copper busbar and the associated injection-molded plastic are connected using common nodes, and the IGBT plastic housing and IGBT heat sink are connected using rigid elements. Other contact surfaces (the lower surface of the tooling head and the upper surface of the IGBT copper busbar, and the lower surface of the IGBT copper busbar and the lower surface of the AC copper busbar) use a surface-to-surface contact algorithm, and the slip type is selected as finite slip. The bolt holes of the IGBT heat sink and AC busbar are constrained, and the simulation model is mounted on the controller.

[0048] In step S303, the relative position of the model is adjusted according to the positional tolerance of the copper busbars to simulate the extreme working conditions within the tolerance zone. The specific working conditions are: 1. The gap between the IGBT copper busbar and the AC copper busbar is at its maximum, and the AC copper busbar is at the lowest position allowed by the tolerance zone; 2. The interference between the IGBT copper busbar and the AC copper busbar is at its maximum, and the AC copper busbar is at the highest position allowed by the tolerance zone; 3. Both the IGBT copper busbar and the AC copper busbar are at the highest position allowed by the tolerance zone; 4. Both the IGBT copper busbar and the AC copper busbar are at the lowest position allowed by the tolerance zone. For the working condition where there is interference between the copper busbars to be welded, a solver needs to be used to solve the calculation model to obtain the prestress and deformation of the model.

[0049] In step S304, a displacement load curve is defined, and a displacement load is applied to the tooling head.

[0050] In step S305, the solver is used to solve the calculation model to obtain data such as the gap of the copper busbar to be welded area and the stress of the plastic structural parts during the tooling pressing process.

[0051] In step S306, the simulation data of the gap in the copper busbar to be welded area and the stress of the plastic structural component are analyzed and evaluated. The relationship between the gap in the to-be-welded area and the tooling displacement for each working condition is as follows: Figure 4 As shown. Based on this result, the displacement range that simultaneously satisfies the welding gap requirements for all working conditions can be determined. For example: setting the maximum allowable gap for the welding process to be 0.15mm, curve 1 shows that when the tooling displacement is greater than 0.40mm, the gap in the area to be welded is adjusted to within 0.15mm; curve 2 shows that when the tooling displacement is greater than 0.46mm, the gap in the area to be welded increases back to above 0.15mm; curve 3 shows that when the tooling displacement is greater than 0.52mm, the gap in the area to be welded increases back to above 0.15mm; curve 4 is within the acceptable range throughout and does not generate constraints, so the usable tooling displacement range is 0.40mm~0.46mm. The stress level of the plastic structural components within this range is then evaluated. If the following situations occur, the structural design or process plan needs to be adjusted: 1. There is no tooling displacement range that satisfies the gap requirements for all working conditions; 2. There is a displacement range that satisfies the gap requirements, but the maximum stress of the plastic structural components within this range exceeds the material's tensile strength (or a certain proportion of the tensile strength).

[0052] In step S307, based on the data analysis conclusions, the available tooling head displacement is obtained.

[0053] In step S308, the copper busbar of the motor controller is pressed according to the displacement of the tooling head obtained from the analysis, so that the gap of the copper busbar meets the welding process requirements.

[0054] According to the method for adjusting the welding assembly gap of the copper busbar in the motor controller proposed in this application, a finite element simulation model of the components in the motor controller is established. The finite element simulation model of the simulated component is installed on the motor controller. The relative position of the finite element simulation model is adjusted according to the positional tolerance of the copper busbar to simulate the extreme working conditions within the tolerance zone, accurately reproduce the extreme working conditions within the tolerance zone, and the extreme working conditions can be simulated and calculated in the early stage of structural design. Under the extreme working conditions within the tolerance zone, a displacement load is applied to the tooling head of the motor controller to simulate the pressing process of the components in the motor controller. The welding area gap of the copper busbar and the stress data of the components are obtained during the pressing process. The components are pressed down through data evaluation without relying on repeated testing of physical components, saving R&D costs and time. The displacement range of the tooling head that meets the pre-set welding process requirements is determined according to the welding area gap. The reference stress data is determined according to the displacement range of the tooling head. The welding area gap is adjusted according to the reference stress data and the stress data of the components to adjust the copper busbar assembly gap. This ensures that the copper busbar assembly meets the welding process requirements and ensures the structural safety of the components during the assembly process through stress data. It can accurately identify the failure of plastic structures. This solves the technical problems of long welding time for copper busbars, insufficient connection between theory and practice, and inability to effectively identify failure modes of plastic structures in related technologies.

[0055] Next, referring to the accompanying drawings, an adjustment device for the welding assembly gap of the copper busbar of the motor controller according to an embodiment of this application is described.

[0056] Figure 5 This is a block diagram of an adjustment device for the welding assembly gap of the copper busbar of a motor controller according to an embodiment of this application.

[0057] like Figure 5 As shown, the adjustment device 20 for the welding assembly gap of the copper busbar of the motor controller includes: a modeling module 210, a pressing module 220 and an adjustment module 230.

[0058] The modeling module 210 is used to establish finite element simulation models of components in the motor controller. The finite element simulation models of the simulated components are installed on the motor controller. The relative position of the finite element simulation models is adjusted according to the positional tolerance of the copper busbar to simulate the extreme working conditions within the tolerance zone. The pressing module 220 is used to apply displacement load to the tooling head of the motor controller under the extreme working conditions within the tolerance zone to simulate the pressing process of the components in the motor controller and obtain the welding area gap of the copper busbar and the stress data of the components during the pressing process. The adjustment module 230 is used to determine the tooling head displacement range that meets the preset welding process requirements according to the welding area gap, determine the reference stress data according to the tooling head displacement range, and adjust the welding area gap according to the reference stress data and the component stress data to adjust the copper busbar assembly gap.

[0059] According to one embodiment of this application, the modeling module 210 is used to acquire component data of the motor controller; identify component names, material properties and contact relationships in the component data; determine component models according to component names; assign material properties and contact relationships to the corresponding components in the component models; and establish finite element simulation models of the components in the motor controller according to the component models.

[0060] According to one embodiment of this application, the pressing module 220 is used to identify whether the limit condition within the tolerance zone is the maximum interference condition; if the limit condition within the tolerance zone is the maximum interference condition, the prestress data and deformation data simulated by the finite element model under the maximum interference condition are obtained; the assembly stress of the copper busbar is calculated based on the prestress data and deformation data.

[0061] According to one embodiment of this application, the pressing module 220 is used to obtain a pre-set displacement load curve; under extreme working conditions within the tolerance zone, a displacement load is applied to the tooling head of the motor controller based on the displacement load curve.

[0062] It should be noted that the explanation of the above-described method for adjusting the welding assembly gap of the copper busbar of the motor controller also applies to the device for adjusting the welding assembly gap of the copper busbar of the motor controller in this embodiment, and will not be repeated here.

[0063] According to the adjustment device for the welding assembly gap of the copper busbar in the motor controller proposed in this application embodiment, the modeling module is used to establish a finite element simulation model of the components in the motor controller. The finite element simulation model of the simulated component is installed on the motor controller, and the relative position of the finite element simulation model is adjusted according to the positional tolerance of the copper busbar to simulate the extreme working conditions within the tolerance zone, accurately reproduce the extreme working conditions within the tolerance zone, and the extreme working conditions can be simulated and calculated in the early stage of structural design; the pressing module is used to apply a displacement load to the tooling head of the motor controller under the extreme working conditions within the tolerance zone to simulate the pressing process of the components in the motor controller and obtain the lower... During the pressing process, the gap in the welding area of ​​the copper busbar and the stress data of the components are used to evaluate the components before pressing, eliminating the need for repeated testing of physical components and saving R&D costs and time. The adjustment module is used to determine the tooling head displacement range that meets the pre-set welding process requirements based on the gap in the welding area, determine the reference stress data based on the tooling head displacement range, and adjust the gap in the welding area based on the reference stress data and the component stress data to adjust the copper busbar assembly gap. This ensures that the copper busbar assembly meets the welding process requirements and also ensures the structural safety of the components during the assembly process through stress data, and can accurately identify the failure mode of the plastic structure. Thus, it solves the technical problems of long copper busbar welding time, insufficient connection between theory and practice, and inability to effectively identify the failure mode of plastic structures in related technologies.

[0064] Figure 6A schematic diagram of the structure of a vehicle provided in an embodiment of this application. The vehicle may include: The memory 601, the processor 602, and the computer program stored on the memory 601 and capable of running on the processor 602.

[0065] When the processor 602 executes the program, it implements the method for adjusting the welding assembly gap of the copper busbar of the motor controller provided in the above embodiments.

[0066] Furthermore, the vehicle also includes: Communication interface 603 is used for communication between memory 601 and processor 602.

[0067] The memory 601 is used to store computer programs that can run on the processor 602.

[0068] The memory 601 may include high-speed RAM (Random Access Memory) memory, and may also include non-volatile memory, such as at least one disk storage.

[0069] If the memory 601, processor 602, and communication interface 603 are implemented independently, then the communication interface 603, memory 601, and processor 602 can be interconnected via a bus to complete communication between them. The bus can be an ISA (Industry Standard Architecture) bus, a PCI (Peripheral Component Interconnect) bus, or an EISA (Extended Industry Standard Architecture) bus, etc. The bus can be divided into address bus, data bus, control bus, etc. For ease of representation, Figure 6 The bus is represented by a single thick line, but this does not mean that there is only one bus or one type of bus.

[0070] Optionally, in a specific implementation, if the memory 601, processor 602, and communication interface 603 are integrated on a single chip, then the memory 601, processor 602, and communication interface 603 can communicate with each other through an internal interface.

[0071] The processor 602 may be a CPU (Central Processing Unit), an ASIC (Application Specific Integrated Circuit), or one or more integrated circuits configured to implement the embodiments of this application.

[0072] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the above-described method for adjusting the welding assembly gap of the copper busbar of a motor controller.

[0073] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0074] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "N" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0075] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or N executable instructions for implementing custom logic functions or processes, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0076] It should be understood that various parts of this application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiments, steps or methods can be implemented using software or firmware stored in memory and executed by a suitable instruction execution system. If implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (FPGAs), field-programmable gate arrays (FPGAs), etc.

[0077] Those skilled in the art will understand that all or part of the steps of the methods implementing the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, the program includes one or a combination of the steps of the method embodiments.

[0078] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A method for adjusting the assembly gap of a motor controller copper bar welding, characterized in that, The method comprises the following steps: establishing a finite element simulation model of the parts in the motor controller, simulating the installation of the finite element simulation model of the parts on the motor controller, adjusting the relative positions of the finite element simulation model according to the position tolerance of the copper bar, and simulating the limit working conditions within the tolerance band; applying displacement load to the tooling press head of the motor controller under the limit working conditions within the tolerance band to simulate the pressing process of the parts in the motor controller, and obtaining the welding area gap of the copper bar and the stress data of the parts in the pressing process; determining the tooling press head displacement range that meets the pre-set welding process requirements according to the welding area gap, determining the reference stress data according to the tooling press head displacement range, and adjusting the welding area gap according to the reference stress data and the stress data of the parts to adjust the copper bar assembly gap.

2. The method of adjusting the welding assembly gap of the motor controller copper bar according to claim 1, characterized in that, The parts in the motor controller include multiple IGBT copper bars, IGBT plastic shells, IGBT heat dissipation bottom plates, AC copper bars, AC bus plastic shells, and tooling press heads.

3. The method of claim 1, wherein the method further comprises: The establishment of the finite element simulation model of the parts in the motor controller comprises: obtaining part data of the motor controller; identifying the part name, material attribute, and contact relationship in the part data; determining a part model according to the part name, assigning the material attribute and contact relationship of the corresponding part to the part model, and establishing the finite element simulation model of the parts in the motor controller according to the part model.

4. The method of adjusting the assembly gap of the copper bars of the motor controller according to claim 3, characterized in that, The material attribute includes at least one of elastic modulus, Poisson's ratio, and stress-strain curve.

5. The method of claim 1, wherein the method further comprises: The limit working conditions within the tolerance band include at least one of the maximum gap working condition, the maximum interference working condition, the highest position working condition allowed by the tolerance band, and the lowest position working condition allowed by the tolerance band.

6. The method of adjusting the welding assembly gap of the motor controller copper bar according to claim 5, characterized in that, Before applying displacement load to the tooling press head of the motor controller under the limit working conditions within the tolerance band, the method further comprises: identifying whether the limit working condition within the tolerance band is the maximum interference working condition; if the limit working condition within the tolerance band is the maximum interference working condition, obtaining pre-stress data and deformation data simulated by the finite element model under the maximum interference working condition.

7. The method of claim 1, wherein the method further comprises: The method of applying displacement load to the tooling press head of the motor controller under the limit working conditions within the tolerance band comprises: obtaining a pre-set displacement load curve; applying displacement load to the tooling press head of the motor controller based on the displacement load curve under the limit working conditions within the tolerance band.

8. An apparatus for adjusting the assembly gap of a motor controller copper bar welding, characterized in that, The method comprises: a modeling module for establishing a finite element simulation model of the parts in the motor controller, simulating the installation of the finite element simulation model of the parts on the motor controller, adjusting the relative positions of the finite element simulation model according to the position tolerance of the copper bar, and simulating the limit working conditions within the tolerance band; a pressing module for applying displacement load to the tooling press head of the motor controller under the limit working conditions within the tolerance band to simulate the pressing process of the parts in the motor controller, and obtaining the welding area gap of the copper bar and the stress data of the parts in the pressing process; An adjusting module is configured to determine a tooling ram displacement range that satisfies a pre-set welding process requirement based on the welding zone gap, determine reference stress data based on the tooling ram displacement range, and adjust the welding zone gap based on the reference stress data and the part stress data to adjust the copper bar assembly gap.

9. A vehicle characterized by comprising: The vehicle includes a motor controller, and the copper bar welding assembly gap of the motor controller is adjusted by using the adjusting method of the copper bar welding assembly gap of the motor controller according to any one of claims 1-7.

10. A computer readable storage medium having stored thereon a computer program or instructions, characterized in that, The computer program or instructions are executed to implement the adjusting method of the copper bar welding assembly gap of the motor controller according to any one of claims 1-7.

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